Abstract

Automatic door is one of the most preferable domestic intended to provide easy
access to enter the house. There are many types of automatic door mechanisms such as
sliding automatic door; rolling up automatic door; circular sliding door; folding wing
door; wing door drive unit etc. designs available today are limited on the above
mentioned. Products available in the market are quite pricy even when installation and
maintenance cost is not yet been consider. Most of the products available in our country
are imported from foreign country.
The objective of our project is to study analyze and develop mechanism that
concern with the cost reduction and the mechanism produced should be safe and reliable
as well. Here a different type of analysis method was used in order to develop a proper
automatic single sliding door mechanism. These methods are finite element modeling and
mechanical design concepts and theories. Stress analysis is done by applying variable
maximum loaded stresses to ensure the product life services sustainable.
Analysis done also helps in order to select proper material and component
specification or sizes for the product development. There fore the durability assessment
results are significant to reduce the cost and improve the product reliability so as to gain
customer confidence.

CONTENTS

CERTIFICATE-----------------------------------------ACKNOWLEDGEMENT-----------------------------ABSTRACT---------------------------------------------CHAPTER ONE Introduction

1.1 Introduction
1.2 Motivation
1.3 Objective
1.4 methodology
CHAPTER TWO-Literature survey
2.1- Door automation
2.2- Back ground
2.3-working principle
2.4-Electrical part
2.4.1-Electrical motor
2.4.2-Sensor
2.5-Mechanical part
2.5.1-Driving units
2.5.1.1-Gear drives
2.5.1.2-Flexible driving units
2.5.2-Power transmission shaft, key & axle
2.6-Programable ladder circuit (PLC)
2.7-design specification
CHAPTER THREE-Design of worm gear drive

PAGE

3.1- Worm gear drive-------------------------------------------------------3.2- Material selection------------------------------------------------------3.3- Direction of rotation in worm gear----------------------------------3.4- Basic parameters of worm wheel and worm-----------------------3.5- Worm design-----------------------------------------------------------3.6- Worm gear design-----------------------------------------------------3.7- Design of worm gearing from stand point of different loads---3.8- Estimation of input power capacity--------------------------------3.9-Force analysis--------------------------------------------------------3.10-Worm shaft design--------------------------------------------------3.11-Timing belt design--------------------------------------------------3.12-Belt drive and driven pulleys design-----------------------------3.13-Worm gear shaft design--------------------------------------------3.14- Worm gear key design----------------------------------------------3.15- pulley supporting Axle design-------------------------------------CHPTER FOUR- DOOR OPERATING COMPONENTS DESIGN
4.1-Determination of door size and shape------------------------------4.1.1-weight and dimensions of door------------------------------4.1.2-Door driving force analysis----------------------------------4.2-Design of beam holding the door at the top-----------------------4.3-Design of door hinging components at the top-------------------4.3.1- Roller design ---------------------------------------------4.3.2- Pin (axel) design ---------------------------------------------------4.3.3-Box channel design-------------------------------------------4.3.4- Cap screw design -----------------------------------------------4.4-Design of door hinging components at bottom-------------------4.4.1- pin (axel) design----------------------------------------------4.4.2-U-channel design----------------------------------------------4.4.3Guide way design----------------------------------------------4.5-Bolt design------------------------------------------------------------

4.6-Column design------------------------------------------------------CHAPTER FIVE- PLC DESIGN

5.1- Introduction--------------------------------------------------------5.1.1- Ladder logic

-----------------------------------

5.2- Objectives -------------------------------------------------------5.3- PLC connections ----------------------------------------------5.3.1- PLC hardware configurations ----------------------5.4- Sensor wiring --------------------------------------------------5.5- Description of the process -----------------------------------5.6- Ladder logic diagram of the program ----------------------CHAPTER SIX -CONCLUSION AND RECOMENDATION
6.1- Conclusion---------------------------------------------------------6.2- Recommendation-------------------------------------------------BIBLIOGRAPHY----------------------------------------------------------APPENDIX-----------------------------------------------------------------PROTOTYPE----------------------------------------------------------------

CHAPTOR ONE: INTRODACTION

1.1 Introduction

CHAPTER TWO

2 Literature survey
2:1 door Automation
Automatic door is one of the most preferable domestic intended to provide
easy access to enter the house with out operator, especially for elderly and people with
disability. There are many types of automatic door mechanism.
1- automatic sliding door
2- Folding wing door
3- Rolling up automatic door
4- Circular sliding door
Automatic sliding door
Automatic sliding doors are available in single slide, bi-part slide and telescopic
slide configurations. As a rule, these are furnished as complete packages and can be
surface mounted or concealed overhead (in-transom mounted). Slide doors typically
include: an operator, header, track, carrier wheels, sliding door panel(s), jambs, lock and
activation/ safety system. Other operations are also available.
Automatic swing doors:
Automatic full-power swinging door operations can either be supplied as complete
packages, or simply as the operator with header and drive arm. They can be mounted for
push and pull applications. Swing door products are designed for single, pair or double
egress applications.

When supplied as a complete package, this will generally include: an operator; header;
door panel(s), jambs, finger protection [if applicable], lock, guide rails and
activation/safety system. When existing door panels are used, then an operator with
header and drive arm are supplied-along with an appropriate activation and safety system.
In all instances, guide rails may be required to protect the swing area of the door panel.
If the doors swing against a natural protective barrier such as a wall, then perhaps the
guide rails can be eliminated.
Automatic folding door
Automatic folding doors are furnished as complete packages. This includes: the operator,
header, pivot hardware, door panels, guide rails, lock and activation/ safety system. They
are offered in either single fold or bi-fold configuration.
Rolling up automatic doors, folding wing doors, and circular sliding doors are
applicable in large industries insurance companies, banks retail and wholesale traffic and
logistic health care etc. but sliding automatic doors are applicable in administration
building entrances. Specifically automatic sliding door is more preferable for this project.
The high degree of comfort provided by automatic sliding door not only enables the
opening of the passage way but also guaranties that they are always reliably closed.
2.2 Historical back ground of automatic door
A$100 investment by collage student in Toledo, Ohio , in1974 planted the seed
from which have grown one of the most successful garage door and automatic gate
systems companies.
When George Elbe placed $100 advertisement in the local newspaper offering 13
automatic door openers, they were all sold and installed. This was the begging of
accompany whose business philosophy included exceptional customer services, with a
sharp focus on customer need, and satisfaction. That philosophy all feature direct access
to all management personal by phone or email and its acre do that continues to this day.
On 1981 after seven years of dramatic growth in Toledo, the decision was made to add a
second location Naples; Fl was chosen as a perfect setting since it combined a great with

rapidly expanding business environment. Utilizing the same business tenors that were so
successful in Toledo, action door and gate welcome its first customer.
An automatically opening doors are powered open and closed either by electrically,
spring or both. There are several methods by which an automatically opening is iterated.
2:3 working principle
Bi-part sliding automatic door is mostly used in leaving houses. It works:
When the person approaches to match to enter the houses its senses and motor
one stands so the door is open to the left at the same time the alarm light will be open and
after the person enters the house and the sensor senses to the motor tow stand and the
door closed. When there is no power to safe used chargeable battery.

Blockdiagram

Sensor

CONTROL
UNIT

MOTOR
DRIVE
UNIT

POWER
SUPPLY

SWITCH

DOOR 1

MOTOR

SWITCH
DOOR 2

2.4- Electrical devices

2.4.1 Electric motor
Industrial motors come in variety of basic types, these are suitable for many different
application.
Some types of motors are:
- Ac motors
-

Dc motors

Servo motors

Bush lens Dc motors

Bushed Dc motors

Stepper motors

Linear motors

Dc motors
Dc motors is one of the earliest motor design. it is a motor of choice in the majority
of reliable speed and torque applications. The reason is the dc motors are in general much
more adaptable to adjustable speed services than ac motors associated with a constant
speed rotating field. In deed, the ready susceptibility of dc motor to adjustment of their
operating speed over wide ranges and by a verity of methods is one of the important
reasons for the strong competitive position of dc machinery in modern industrial
applications.

Advantages of Dc motor
-

easy to design

easy to control speed

easy to control torque

simple, cheap drive design

2.4.2 [A sensor]

sensors for automatic are generally.

A pressure sensor: e.g. a floor met which reacts to the pressure of some one
standing on it.
An infrared (curtain) or beam which shines invisible light on to sensor, if some one
or something blocks the beam the door is triggered open.
A motion sensor (e.g. based on infrared or radio waves can be triggered by a
portable [remote control] or installed inside a vehicle; these are popular for garage doors.
A switch is operated manually, perhaps after security checks. This can be a push
button switch or swipe canal. The act of pushing or pulling the door triggers the open and
close cycle.
LOGICAL SENSORS
Sensors allow a PLC to detect the state of a process. Logical sensors can only detect a
state that is either true or false. Examples of physical phenomena that are typically
detected are listed below.
Inductive proximity - is a metal object nearby?
Capacitive proximity - is a dielectric object nearby?
Optical presence - is an object breaking a light beam or reflecting light?
Mechanical contact - is an object touching a switch?
PRESENCE DETECTION
There are two basic ways to detect object presence; contact and proximity. Contact
implies that there is mechanical contact and a resulting force between the sensor and the
object. Proximity indicates that the object is near, but contact is not required.
Contact Switches
Contact switches are available as normally open and normally closed. Their housings are
reinforced so that they can take repeated mechanical forces. These often have rollers and
wear pads for the point of contact. Lightweight contact switches can be purchased for less
than a dollar, but heavy duty contact switches will have much higher costs. Examples of
applications include motion limit switches and part present detectors.

Reed Switches
Reed switches are very similar to relays, except a permanent magnet is used instead of
a wire coil. When the magnet is far away the switch is open, but when the magnet is
brought near the switch is closed.

Optical (Photoelectric) Sensors

Optical sensors require both a light source (emitter) and detector. Emitters will
produce light beams in the visible and invisible spectrums using LEDs and laser diodes.
Detectors are typically built with photodiodes or phototransistors. The emitter and
detector are positioned so that an object will block or reflect a beam when present.
An emitter can be set up to point directly at a detector, this is known as opposed mode.
When the beam is broken the part will be detected. This sensor needs two separate
components.
This arrangement works well with opaque and reflective objects.

Capacitive Sensors
Capacitive sensors are able to detect most materials at distances up to a few centimeters.
For this sensor the proximity of any material near the electrodes will increase the
capacitance. This will vary the magnitude of the oscillating signal and the detector will
decide when this is great enough to determine proximity
These sensors work well for insulators (such as plastics).
Inductive Sensors
Inductive sensors use currents induced by magnetic fields to detect nearby metal objects.
The inductive sensor uses a coil (an inductor) to generate a high frequency magnetic
field. These sensors will detect any metals, when detecting multiple type of metal
multiple sensors is often used.

Ultrasonic
An ultrasonic sensor emits a sound above the normal hearing threshold of 16KHz. The
time that is required for the sound to travel to the target and reflect back is proportional to
the distance to the target.
The two common types of sensors are;
Electrostatic - uses capacitive effects. It has longer ranges and wider bandwidth, but is
more sensitive to factors such as humidity.
Piezoelectric - based on charge displacement during strain in crystal lattices. These are

rugged and inexpensive.

These sensors can be very effective for applications such as fluid levels in tanks and
crude distance measurement.

Selection of sensor
Sensor to be selected for this project is:
Light weight contact switches for door motion switch, and optical (photoelectrical) sensor
of opposite mode PNP type.
2.5 Mechanical components or parts.
2.5.1

Mechanical driving systems.

2.5.2

The followings are the most common driving system,

1 - Gear
2 - Chains
3 Belts
4- Ropes
2.5.1-Gear drives:
Gear drives are used machine (engine) parts mainly used for reduction or increasing the
speed gear drive types,
-spure gear
-helix gear
-rack and pinion gear
- Worm and worm wheal
The more disadvantages of using gear is noise and also lubricants are necessary.
Manufacturing is comparatively difficult

Applications of gears

Many power producing machines or prime movers such as internal combustion(IC)

engines, industrial gas turbine engines and electric motors produce power in the form of
rotary motion.
Dynamic effects of gears
When pain of gears is driven at moderate or with speeds and noise is generated.

Disadvantages of gears
1 failures of surface (wear)
2 pitting surface fatigue failure due to many repetitions of high
Contact stresses.
3 scoring (lubricating failure)
4 abrasions (wear due to the presence of foreign materials)
Advantages of gears.
Power loses at low tooth mush for spur gears are usually less than one percent of the
power transmitted.
Type (kinds) of gears
-Spure gear the teeth are cut straight with respect to the axis of rotation.
- Rack and pinion gear
- helical gear
- worm and worm wheal
- bevel gear
Helical gear
Helical gear is in which the teeth are cut at an angle with respect to the axis of rotation,
is a later development than spur gear and has the advantage that the action is smoother
and tends to be quitter.

-the load transmit ion may be some what large.

- The life of the gears may be greater for the same loading than with an equivalent
pain of spur gears.
Helical gears are most often used in parallel axis arrangement; they can also be
mounted on non-parallel non complainer axis,

Types of helical gear

1) Single
2) double conventional
3) Double staggered
4) Continuous (herring bone)
Advantages over spure gear
1 - Noisy
2 - Load capacity
3 -manufacturing
SELECTION OF GEAR DRIVE
Gear drive preferred for this project is worm and worm gear drive. Worm gearing were
selected to reduce motor speed with 53:1 ratio.

2.5.1.2 Flexible machine elements: Such as belts ropes chains are used for
transmission of power over comparatively long distance. When these elements are
employed they usually replace a group of gears, shafts, and bearings or similar power
transmission devices. They greatly simplify a machine and consequently are a major cost
reducing element.
In addition, since these elements are elastic and usually long, they play an important
part is absorbing shock loads and is damping out the effects of vibrating forces. Although
this advantage is important as a concerns the life of the driving machine; the cost
reduction elements is generally is the major factors in the selection of this means of
power transmission.

Chain drive: The most common type of chain drive is roller chain.
Basic features of chain drives include a constant rotation, since no slippage or
creep is involved; long life and the ability to drive a number of shafts from a single
source.
When chain drives are used to synchronize precision components or processes, due
consideration must be given to the cordial speed variation.
Chain drives disadvantage: At higher speeds the cyclic impact between the
chain links and the sprocket teeth, high noise and difficulties in providing lubrication,
limit the application of chain drives.
Application range: From motor cycle and bicycle transmissions, automotive
cam shafts drives, machine tools and aerospace drives, such as the thruster nozzles for
harrier, to conveyors and packaging machinery.
Roller chains seldom fail because they lack tensile strength; they more often fail
because they have been subjected to a great many hours of services.
Actual failure may be due to either wear of the rollers on the pins or to fatigue of the
surface of rollers.
Disadvantages:
-

Lubrication of roller chain is essential in order to obtain a long and trouble free life.

Noisiness of the system.

Belt:
Belts are used to transmit power between two parallel shafts. The shafts must be
separated a certain minimum distance, which is dependant up the type of belt used, in
order to work most efficiently.
Characteristics:

They may be used for long center distance. Because of the slip and creep of
belts, the angular velocity ratio between the two shafts is neither constant nor exactly
equal to the ratio of the pulley diameter.
When using flat belts, clutch action may be obtained by shifting the belt from a loose
to a tight pulley.
When V belts are used, some variation in the angular velocity ratio may be
obtained by employing a small pulley with spring loaded sides. They varied by changing
the center distance. Some adjustments of a center distance are usually necessary when
belts are used.
By employing step pulleys, an economical means of changing the velocity ratio
may be obtained.
Types of belt
1-flat belt
2-V belt
3-Timing belt
Flat belts:
The modern flat belt consists of a strong elastic core, such as steel or nylon cords.
To take the tension and transmit the power combined with a flexible envelope to provide
friction between the belt and pulley.
Advantages:
-Flat belts are very efficient for high speeds.
-They are quiet.
-they can transmit large amount of power over long center distances.

Disadvantages of flat belt:

- They dont require large pulley.

- They can transmit power around corners or between pulleys at right angles to each
other.
Flat belts are particularly use full in group drive installations because of the
clutching action that can be obtained.

V-belts:
V-belt is made of fabric and cord, usually cotton, rayon or nylon, and impregnated
with rubber. In contrast to flat belt, v-belts are used with smaller sheaves and at shorter
center distance.
V-belts are slightly less efficient than flat belts, but a number of them can be used
on a single sheave, thus making a multiple drives. They are endless, which eliminates the
joint used in flat belts.
Timing belt:
A timing belt also cold a tog belt, is made of rubberized fabric and steel wire,
having teeth with fit in to grooves cut on the periphery of the pulleys. The timing belt
does not stretch or slip and consequently transmits power at a constant angular velocity
ratio. The face that the belt is toothed provides several advantages over ordinary belting.
1 No initial tent ion is necessary so that fixed center device may be used.
2 the elimination of the restriction on speeds; the teeth make it possible to run at nearly
any speed, slow or fast.
Disadvantage of Timing belt
Cost of the belt, the necessity of grooving the pulleys and the attendant dynamic
fluctuations caused at the belt tooth meshing frequency.

Comparison of chain belt and gear performance A,(excellent ); B,(good); C,(poor).

Feature

Efficiency
Large center distance

Chain drive

Belt drive

Gear drive

Wear resistance

Multiple drive

Heat resistance
Chemical resistance

Oil resistance
Power range
Speed range
Ease of maintenance
Environment

Rope drives:
Rope drives consists of manila, cotton, or Dacron rope on multiple grooved pulleys
may often be a most economical form of drive over a long distance and for large amounts
of power. Accurate alignment of the pulley is not necessary because they are grooved.
The velocity of the rope should be quite high 25m/s is a good speed for greatest
economy.

Fasteners (bolt and screw)

Differentiation between bolt and screw

A carriage bolt with square nut
A structural bolt with a hex. Nut and washer.
There is no universally accepted distinction between a screw and a bolt. A bolt is an
externally threaded fastener designed for insertion through holes in assembled parts, and
is normally intended to be tightened or released by torquing a nut. A screw is an
externally threaded fastener capable of being inserted into holes in assembled parts, of
mating with a preformed internal thread or forming its own thread, and of being tightened
or released by torquing the head. An externally threaded fastener which is prevented from
being turned during assembly and which can be tightened or released only by torquing a
nut is a bolt. (Example: round head bolts, track bolts, plow bolts.) An externally threaded
fastener that has thread form which prohibits assembly with a nut having a straight thread
of multiple pitch length is a screw. (Example: wood screws).
Sheet metal screw
Sheet metal screw has sharp threads that cut into a material such as sheet metal, plastic
or wood. They are sometimes notched at the tip to aid in chip removal during thread
cutting. The shank is usually threaded up to the head. Sheet metal screws make excellent
fasteners for attaching metal hardware to wood because the fully threaded shank provides
good retention in wood.

Fig - sheet metal screw

Hex. Cap screw

hex bolt
A hex cap screw is a cap screw with a hexagonal head, designed to be driven by a
wrench (spanner). An ASME B18.2.1 compliant cap screw has somewhat tighter
tolerances than a hex bolt for the head height and the shank length. The nature of the
tolerance difference allows an ASME B18.2.1 hex cap screw to always fit where a hex
bolt is installed but a hex bolt could be slightly too large to be used where a hex cap
screw is designed in.

Fig _ hexagonal bolt

Materials
Screws and bolts are made from a wide range of materials, with steel being
perhaps the most common, in many varieties. Where great resistance to weather or
corrosion is required, stainless steel, titanium, brass (steel screws can discolor oak and
other woods), bronze, Monel or silicon bronze may be used, or a coating such as brass,
zinc or chromium applied. Electrolytic action from dissimilar metals can be prevented
with aluminum screws for double-glazing tracks, for example. Some types of plastic,
such as nylon or polytetrafluoroethylene (PTFE), can be threaded and used for fastening
requiring moderate strength and great resistance to corrosion or for the purpose of
electrical insulation.
2.6 Controlling mechanisms
Control systems apply artificial means to change the behavior of a system. The type of
control problem often determines the type of control system that can be used. Each
controller will be designed to meet a specific objective.
The major types of control are:

Fig______. Control Dichotomy.

Continuous - The values to be controlled change smoothly. e.g. the speed of a car.
Logical - The value to be controlled are easily described as on-off.
Linear - Can be described with a simple differential equation. This is the preferred
starting point for simplicity, and a common approximation for real world problems.
e.g. A car can be driving around a track and can pass same the same spot at a constant
velocity. But, the longer the car runs, the mass decreases, and it travels faster, but requires
less gas, etc. Basically, the math gets tougher, and the problem becomes non-linear.
Non-Linear - Not Linear. This is how the world works and the mathematics become
much more complex.
Sequential - A logical controller that will keep track of time and previous events.
Logical and sequential control is preferred for system design. These systems are more
stable and often lower cost.
Many control technologies are available for control. Early control systems relied upon
mechanisms and electronics to build controlled. Most modern controllers use a computer
to achieve control. The most flexible of these controllers is the PLC (Programmable
Logic Controller).
SELECTION OF CONTROLLER
For this project, the selection of controlling mechanism of a system to be the most
modern controller, which uses computer is (programmable logic controller) PLC.
Programmable logic circuit (PLC)
Control system is a collection of electronic devices and equipment which are place
to ensure the stability, accuracy and smooth transition of a process or a manufacturing
activity.

Typical applications of PLC

In robot control machine, it used in a pick and place operation. The whole process
sequence is controlled by PLC.
The roll of PLC
In an automated system, the PLC is commonly regarded as the heart of the control
system with the control application program(stored within the PLC memory) in
execution, the PLC constantly monitors I.e. state of the system through the field input
devices feed back signal. It will base on the program logic to determine the cause of
action to be carried out at the field output devices.
The PLC may be used to control a single and repetitive task, or a few of them may
be interconnected together with other host controllers or host computers through a short
of communication network, in order to integrate the control of a complex process.

2.7 DESIGN SPESIFICATION

CHAPTER THREE:

DESIGN OF WORM GEAR DRIVE

3.1- WORM GEAR DRIVE

Worm gearing is widely used to transmit power at high velocity ratios between non
intersecting shafts.
Before designing speed reduction worm gearing we have to calculate the out put speed
from the specification of door linear sliding speed.
The sliding door is specified to speed (v)=0.5m/s so the belt speed also the same. Let the
pitch diameter of pulley attached to the out put shaft speed is 120mm.

From dynamics we have tangential speed

V=wr
w=2
V=2 ngr/60
ng=30*V / r
ng= (30*0.5/ 0.06) rpm
ng=79.577rpm=80rpm

d=120mm=0.12m
r=0.06m

ng=80rpm is the speed of out put shaft (worm gear)

3.2 MATERIAL SELECTION

The selection of materials for the worm and the worm gear is more limited than it is for
other types of gears. The threads of the worm are subjected to fluctuating stresses and the
number of stress cycles is fairly large. There fore the surface endurance strength is an
important criterion in the selection of the worm material. The core of the worm should be
kept ductile and tough to ensure maximum energy absorption. The worms are, there fore
made of case hardened steel.
The magnitude of contact stresses on the worm gear teeth is the same as that on the worm
gear threads. However, the number of stresses cycles is reduced by a factor equal to the
speed reduction. The worm gear cannot be accurately generated in the hubbing processes.
There fore the worm gear material should be soft and conformable. Phosphor bronze,
with a surface hardness of 90 120 BHN, is widely used for the worm gear.
There are tow reasons for using dissimilar or heterogeneous material for worm and worm
gear.
i)
the coefficient of friction is red uced.
ii)
The conformability of worm gear with respect to worm is improved.
The following material will be used
Worm
Gear
Hardened steel
Cast iron
Steel, 250BHN
Phosphor bronze
Hardened steel
Phosphor bronze
Hardened steel
Chilled Phosphor bronze
Hardened steel
Antimony bronze
Cast iron
Phosphor bronze

B(KN/m2)
345
415
550
830
830
1035

Where B a constant depending up on the combination of the materials used for the
worm and worm gear as listed above. The above values for B are suitable for lead angle
up to 100 for angle between 100 and 250 increase B by 25%for lead angle greater than 250
increase B by 50%.
Let be hardened steel are (uts=520N/mm2) and phosphor bronze (uts=320n/mm2)
for worm p allowable stresses =120N/mm2 worm gear respectively will be selected for
the design.
3.3 DIRECTIONS OF ROTATION IN WORM DRIVES
A worm may be classified as right-handed or left-handed. Depending up on the direction
of helix of the worm threaded in which the thread winds around the root cylinder.
Normally right handed worms are used in preference to left handed worm which are

used in case especial requirement. So that in this project the worm is a right-handed
,direction of rotation is a worm and a worm wheel system of drive depends up on the
direction of helix and the position of wormwheel.see clearly the following figure

Fig direction of rotation of worm drive.

3.4 Basic dimensions and parameters of worm and worm gear

3.5 WORM DESIGN

?
Let Nw= (doublestart )
Ng = 70

-high speed reduction

Ng = 80 rpm (calculated)
Center distance(C) =80mm

The recommended number of starts on worm is

Velocity ratio(R)
20 and above
12 36
8 12
6 -12
4 -10

Velocity ratio =

R=

R=35

Number of start (Nw)

Single start
Double start
Triple start
Quadruple start
Sextuple start

nw
Ng
= ng
Nw

70
nw
nw
=
= 35=
2
80
80

nw =35*80rpm=2800rpm
Nw =2800rpm

Since the angle of shaft between worm and gear is 900 in our case, the lead angle ( ) on
the worm and helix angle ( ) on the gear are equal.
Axial pitch (pa) of the worm and circular pitch (pc) on the gear are equal

Pc=pa
From standard modules preferred values of (m)
1, 1.25, 1.5, 2, 2.5, 3, 4, 5, 6, 8, 10, 12 .
Let m=2mm
Pitch (pa) = m= * 2 =6.283mm, say (pa) =6mm
Lead (L) =NW*pc=2*6=12mm
Dg

Pa=pc= Ng , Dg=

pc * Ng
6 * 70
=(
)

Dg=133.69 134mm
Pitch diameter of gear (Dg) =134mm
According to AGMA recommendations
Dw
Dw

c 0.875
=3pc
3.48

3*6.283mm=18.849mm 20mm
Dw=20mm

Center distance (C) =

Dw Dg
=
2

20 140
= 80mm
2

C = 80mm
Lead angle ( ) will be
lead ( L)
12
tan =
=
= 0.190985
* 20
* Dw

= tan-1(0.190985)
= 10.810

Length of thread portion (worm length)

Lw = pa (4.5+0.02Nw) = 6(4.5+(0.02*2)=27.24mm
The length should be increased by 25 to 30mm for feed marks produced by the vibrating
grinding wheel as it leaves the thread root.
There fore, take us, Lw = 38mm
Depth of tooth h=0.623pa = 0.623*633.73mm say 4mm
Addendum (ha1) =m =2mm
Dedendum (hf1) = (2.2cos10.810-1) m=(2.2cos10.810-1)*2=2.3mm
Clearance (Cc)=0.2mcos = 0.2*2*cos10.810 = 0.39mm
Out side diameter of worm (da1) =DW+2hf1
=20+ (2*2) =24mm
Root diameter of worm (df1) = Dw-2hf1

= 20-(2*2.3) =15.4mm
Normal pressure angle ( n ) must be large enough to avoid under cutting of the gear
tooth on the slide at which the contact ends. It is depending up on the lead angles in the
worm gearing.
Recommended pressure angle in relation to lead angle

Up to 150
Over150 up to
Over 250 up to
250
350
0
0
n
20
22.5
250
There fore, =200 , for
q(diametric quotient)=

=10.810

dw 20
=
= 10 (standard)
m
2

2.6 WORM GEAR DESIGN

Let number of teeth in the worm gear=Ng= 70
Pitch circular diameter of worm gear,
Dg = m*Ng=2*70 = 140mm
Addendum (ha2) = m (2 * cos -1) = 2(2*cos10.810-1) = 1.93mm
Dedendum (hf2) = m (1+0.2cos ) = 2(1+0.2cos10.810) =2.4mm
Out side diameter of gear (da2) = Dg+2ha2
=140+2*1.93
=143.86mm
Say 144mm
Root diameter (df2) = Dg-2hf2
= (140-2*2.4)
=135mm
Face width =2.15+pa = 2.15*6+5
= 17.9mm

say

18mm

Design of worm gearing parameter can be checked.

c 0.875
dw c0.875
3
1.7

(80)0.875
20 800.875
3

15.4 20 27

Over 350
300

It is ok
Gear ratio(R) =

Dg
Dw tan

35 =

140
20 * tan 10.81

35 36.6
OK.

From motor we have power output=120w after gear reduction and

rpm=80rpm.
The d.c motor used in this project is with worm gearing attached on it.
So the motor (input and input speed) is not known.
From worm gearing analysis we have
=2800rpm (calculated)
=80rpm (given)
=20mm (calculated)
=140mm (calculated)
Power output (

) =120w (given)

Power input ( ) =?
Assume
-The worm is right handed and the gear rotates c.w
-power output is not equal to power input because of friction
Pressure angle (

) =20

Lead angle ( ) =10.81(calculated)

?
Required components of forces are

_tangential force on worm (

_tangential forces on gear (

)
)

_the separating force ( )

3.7 Design of worm gearing, from standard points of different loads
A) Tangential load (Ft)
Torque transmitted by the worm gear
T
Ft
Peripheral /pitch line velocity of worm gear

Velocity factor, CV
Tooth form factor(y) for

is by interpolating

Y
The worm gear is generally made from a phosphor bronze, and
hence takes the allowable static stress for phosphor bronze

According to the Lewiss equation the permissible tangential tooth

load of gear

Where

b
m

module

B) Dynamic load (

It is usually not so sever, due to the sliding action between the worm and
worm gear.

Where

since

is more than

The design is safe from the stand point of dynamic load.

C) Static load or endurance strength(F)

Where

flexural endurance limit its value may taken

as 168Mpa for phosphor bronze gear.

Since

is much more than

204.6N the design is safe from the

stand point of static load or endurance strength.

D) wear load (

The limiting maximum load for wear (

Where B=load stress factor or material combination factor B=550Kw/

Since

E) Heat dissipation
First of all efficiency of the worm gearing should be determined.
The efficiency of worm gearing may be defined as the ratio of work done
by the worm gear to the work done by the worm.
Mathematically efficiency (ph) =
Where

normal pressure angle, N=coefficient of friction,

lead

angle.
In order to find the approximate value of the efficiency, assuming square
threads and the following relation is used.
Efficiency (by substituting in the above equation,

)for square

threads).
Ph
Where
The coefficient of friction varies with the rubbing speed

is shown in fig.

From graph for

2.985m/sec,

0.03

Therefore angle of friction,

1.718 .

ph
85.93
Since ph>50%, the worm gearing is not self locking.
In worm gearing, the heat generated due to the work lost in friction
must be dissipated in order to avoid over heating of the drive and
lubricating oil.
The quantity of heat generated (
Where

) is given by
=power transmitted in watt.

Ph=

Heat generated must be dissipated through the lubricating oil and

wall to the atmosphere. The heat dissipation capacity depends up on the
following factor.
Area of the housing (A)
Temperature difference between the housing surface and surrounding air
(

) I.e. the maximum temperature (

) should not Exceed 27

to 38 .
Conductivity of the material (k), i.e. the average value of k may be
taken as 378W/

Mathematically the heat dissipated capacity,

Where

=temp of lubricant oil ( )

=temp of surrounding air ( )

Assume 0.25%over load heat, heat dissipated,

=P (1-ph)
=1.25
Let projected area of the worm =

and projected area of the worm gear =

.
.

Therefore A=

15,707.963

15707.963

15,707.963

3.8 Estimation of input power capacity

) From the stand point of strength of the teeth /tangential load.
Power transmitted due to the tangential load,
P

1354.696N 0.5864m/sec 794.39W

Since the power is more than the given power to be transmitted (140W),
therefore the design is safe from the stand point of the tangential load.
) from the stand point of the dynamic load,

Power transmitted due to the dynamic load,

P

1488.676 0.5864W 872.96W

Since the power is more than the given power to be transmitted (
), the design is safe from the stand point of dynamic load.

) from the stand point of the static load or endurance strength,

Power transmitted due to the static load,
P
Since the power is more than the given power to be transmitted

=140W,

the design is safe from the stand point of the static load.
V) from the stand point of the wear (using AGMA formula)
P

where

=2800rpm

R (transmission ratio) =35

K=pressure constant value for center distance(c)
Q=
=velocity facto
=

Q=

R
35
=
= 0.93
R 2.5
35 2.5

Vw =

* Dw * nw
* 20 * 2800
=
= 2.932m/s
60000
60000

2.3
(3 * 2.932) = 0.4196
Cv =
2.3 2.932
35

Center distance (c)mm

25
50
75
100
;

K(kw/rev/min)
0.0092
0.0184
0.0294
0.0661
:

Table pv assure constant (k) value for center distance (c)

C = 80mm (k), can be determine by interpolation
100 80 = 0.0661 k
80 75
k 0.0294

K = 0.03674
P=

nw * k * Q * cv
2800 * 0.03674 * 0.93 * 0.4196
=
R
35

P = 1.14696KW
Since the power is more than the power to be transmitted (pi = 140w), there fore the
design is safe from the stand point of the wear for AGMA formula.
V) From the stand point of wear load. Power transmitted due to the wear load.
P = Fw*Vg = 1732.5N*0.5864m/s = 1015.9w
Since the power is more than the power to be transmitted (pi =140w), the design is safe
from the stand point of wear load.
Vi) From the start point of heat dissipation. Permissible in put power.

P=

3650(c )1.7
R5

3650(0.08)1.7
= 1.2459kw
35 5

Where c = center distance

R = transmit ion ratio

Since the power is more than the power to be transmitted (pi= 140w), the design is safe
from the stand point of heat dissipation.
The heat generated must be dissipated in order to avoid over heating of the drive ,
therefore (i.e. assuming over load).

Qg = Qd = 21.105w = 5.9376(t 2 - t 1 )

(t 2 - t 1 ) =

21.105w
5.9376 w / c 0

t 2 - t 1 =3.56c 0
Since the temperature difference by assuming over loading is not exceed 27c 0 to 38c 0 ,
it is safe from stand point of heat.
3.9 FORCE ANALYSIS
The analysis of three components of the resultant tooth force between meshing teeth of
worm and worm gear is based on the following assumptions.
i)
The worm is the driving element, while the worm gear is driven element.
ii)
The worm has right handed threads
iii)
The worm is rotate in anti clock wise direction.

Fig

Force acting on the worm gear is equal and opposite reaction of the force acting on the
worm.
Ftg = -(Faw)
Fag = -(Ftg)
Frg = -(Frw)

Ftw =

Mtw
= 47.75N ) (calcula
rw

(calculated)
Ftg = 212.3N = _(Ftw)
Fr = 43.54 N

The resultant force acting on the worm consists of tow components viz. components of
normal reaction between the meshing teeth and components of frictional force. The tow
components of normal reaction W acting on the worm are shown.
P=W=F

, Pa=Fa =WA , PN =FN = Wn ,Pr= Fr =WR Pt=Ft=Wr

FIG

Fig components of normal reaction on worm.

Resolving the normal reaction W in the plane ABCD fig B
Wn = wcos n : wr = wsin n
Resolving the component wn in plane AEBF fig c
Wa =wn* cos
: WT = wn*sin
From above relation ships
Wt=wn*cos n sin : wa = wcos n cos , wr = wsin n
The frictional force is significant in worm gear drives, because the motion between the
worm and the worm wheel is sliding. The resultant force is Nw, where N = coefficient of
friction. The directional force will be along the pitch helix and opposite to the direction of
reaction as shown in fig.

FIG

Components of friction force on worm.

There are tow components of frictional force.
i)
Component (Nwcos ) is in tangential direction, the direction is same as that
of Wt.
ii)
Component (Nwsin ) is the axial direction .the direction is opposite to that
of Wa.
Super imposing the components
cos n cos N sin

Wa= wt* cos n sin N cos

sin

Wr = wt* cos n sin N cos

From the previous calculation (tangential force acting on worm)
WTn =

2Tn
P * 60
140 * 60
, Tw =
=
=477.5Nmm
Dw
2nw
2 * 2800

WTw =

2 * 477.5
= 47.75N
20

N = 0.03

= 10.81

n 20

Axial force on the worm considering frictional force

Wan= 47.75*

cos 20 cos 20 cos 10.81 0.03 sin 10.81

cos 20 sin 10.81 0.03 cos10.81

Radial force considering frictional force.

Wr = 47.75*

sin 10.81
cos 20 sin 10.81 0.03 cos 10.81

WR = 43.54N

=212.9N

Wtg= -waw=-212.9N
Wag = -wtw = -47.75N
Wrg = -wrw = -43.54N
Resultant
W = WR 2 WA 2 WT 2
W=

( 43.54) 2 ( 212.9) 2 ( 47.75) 2

W = 222.49N
Power transmition shaft design
Shaft design consists primarily of the determination of the correct shaft diameter
to ensure satisfactory strength and rigidity when the shaft is transmitting power under
various operating and loading conditions.
Shafts are usually circular in cross section and may be either hollow or solid.
Design of shafts of ductile materials, based on strength, is controlled by the
maximum shaft theory.
The following presentation is based on shafts of ductile material and circular
cross-sections.
Shafting is usually subjected to torsion, bending and axial loads.
In this project tow rotating shafts will be designed one shaft for transmitting
power from motor and the other is out put the reduced speed to slide the door.
Selection of material for shafts
The shaft to be made of plain carbon steel 30 c8 (syt=400N/mm2) and take factor
of safety is 3.
3.10 Design of worm shaft
Assumptions
_ Neglect the weight of shaft
_ the shaft is subjected to both bending and tensional moments.
_ By using maximum shear stress theory of designing the shaft.
Consider the weight of the worm
w*g*area*Lw
w = 7850kg/m3
Ww =
* (0.02 2 )
= (7850*
*0.038*9.81) N
4

Ww=0.92N

FIG

Bending moment diagram

FIG

Permissible shear stress is syt = 400N/mm2 FOS = 3

max =

Ssy
fos

0.5Syt
0.5( 400)
=
=66.67N/mm2
fos
3

Mtw=

p * 60
2 * nw

= 477.46Nmm

16

max
d3 =

d 3

16
* max

( Mb) 2 ( Mt ) 2

(2128.98) 2 (477.46) 2

d =5.5mm = 8mm
Design for torsion rigidity of worm shaft

Based on permissible angle of twist which is vary 0.3deg/m for machine tool shafting to
about 3 deg/m for line shafting modulus of rigidity (G) for steel = 80KN/mm2

584 MtL
Gd 4

Mt = 477.46Nmm
d = 8mm
L = 23mm

584 * 477.46 * 23
80 * 10 3 * 8 4

= 0.01957 deg
OK
L=23mm which is the distance between worm teeth center to bearing
Or
Permissible twist angle ( ) =
d4 =

3( L) 3 * 23

=0.069deg
1000 1000

584 * 477.46 * 23
584 MtL
=
G
80 * 10 3 * 0.069

d = 5.8mm 8mm safe.

3.11 TIMING BELT
Synchronous timing belts are basically end less flat belts which pass over pulleys, belts
having grooves, which mate with teeth on the pulleys. These belts are used for power
transfer and for synchronized drives to ensure that the driven is always rotating at a fixed
speed ratio to the driving pulley.

CONSTRUCTION
Belt synchronous belt are made with elastomer. Eg, natural rubber, neoprene, polureth
are, core with reinforcement to provide increased tensile strength. These belts were
originally rain forced with steel to provide the necessary strength.
Pulley synchronous drive pulley are offer made of ductile or cast iron. Aluminum is
offer selected for drives that require low weights. For this project the selected pulley
material will be aluminum to decrease the weight of the column.

TIMING BELT DESIGN ANALYSIS

By using power method;
1) estimating the design power to be transferred (kw)
P d =service factor *power to be transmitted. (S f *P)

P = 0.120kw
S f = 1.4 from table
p d = 1.4*0.120kw = 0.168kw
Service Factor Applicable to Belt Drives
Introduction
Selecting service factors for drive systems is a very imprecise science and it is
recommended that the engineer use the information provided by the drive system
supplier for detailed design work. The table below is provided to indicate in general, the
level of service factor to apply for drive systems based on some knowledge of the driver
equipment, the driven equipment and the operating period.
Some judgment is required in applying service factors for it is clear that a well designed
drive includes provisions i.e flywheels, slipping clutches, fluid couplings etc which will
effectively isolate the loads providing relatively smooth drive conditions even with load
which have high levels of shock loading.
Service Factors Synchronous Drives
Operating Period /day
< 8 h < 16 h > 16 h < 8 h

Driven
Equipment;

|
v

< 16 > 16
< 8 h < 16 h >16 h
h
h

Driving
Driving
Driving
:Moderate
Machine:Heavy
Machine:Smooth
Vibration
Vibration
Starting torque 100%
Starting torque Starting torque 250%
- 150% FL
150% - 250% FL - 400% FL
Electic Motors -Star
Delta
DC motors-shunt
wound
IC engines over 8
cyl'rs
Water Turbines
Steam Turbines

AC motors
starting torque
IC engines with
4-6 cylinders

AC Motors (DOL)
Two stroke Engines
IC engines under 600
rpm,

Instrumentation
Office display
equipment
Medical Equipment

1.2

1.4

1.1 1.3

1.5

1.2

1.4

1.6

Domestic Appliances
Oven Screens
Woodworking Drills

1.1

1.3

1.5

1.2 1.4

1.6

1.3

1.5

1.7

3) Determination of teeth on pulley

Pitch diameter of pulley = number of teeth on pulley*
Module (m) =

pitch

9.525

pitch

= 3.032mm

Number of teeth on pulley (z p ) =

Dp
120
=
= 39.579
3
.032
m

Number of teeth on pulley (z p ) = 40

4) Belt contact length of pulley (c L ) =

D p *

2
5) Belt length (L) = 2c + 2c L
= [(2*2700) + (2*188.5)]
L = 5777mm

6) Total number of teeth on belt is

120 *
= 188.5mm
2

C=[

p * ( zb z p )
2

where c center distance

P - Pitch
z b - Number of teeth on belt
z p - Number of teeth on pulley

zb =

2*c
+z
2

zb =

beltlength
- - (**)
pitch

- - (*)

Using equation (*)

zb =

2 * 2700
+ 40 = 606.92
9.525

z b = 607
7) number of teeth in mesh (N.T.I.M)
N.T.I.M =

beltcontactlengthofpulley
(c L )
toothpith

N.T.I.M =

188.496
= 19.789 (rounded to the nearest whole number)
9.525

N.T.I.M = 20
8) based on number of teeth in mesh find the teeth in mesh factor from table

`
Number of teeth in mesh
6 or more
5
4
3
2

Teeth in mesh factor

1
0.8
0.6
0.4
0.2

: Teeth in mesh factor is one (1)

9) design torque (T d ) =

peaktorque (Tp )
teethinmeshfactor

powerin *
angularvelocityofwormgearshafty

Peak torque =

120 * 60
2 * * 80

T p = 14.32Nm/1

=14.32Nm

10) Calculate the effective tension(T e )

Td
14.3239( Nm)
T e = 16 * r =
(16 * 0.06)m
p

T e = 14.92N
11) Divide the basic power /design power to obtain a belt width factor.

B.W.F =

0.12 KW
= 0.71
0.168 KW

B.W.F = 0.71
Using the table and select a width with wide factor higher than the calculated
width factor from table belt width (b) = 25.4mm for width factor (1)
Table of Belt Width Factors Belt Width
Belt
Section 3,05 4,826 6,35 9,652 12,7 19,05 25,4 38,1 50.8 76,2 101,6 127
MXL

0,43 0,73 1,00 -

XL

0,62 1,00 -

0.45 0.72 1.00 -

0,21 0,29 0,45 0,63 1,00 -

XH

0,45 0,72 1,00 -

XXH

0,35 0,56 0,78 1,00

3.12 DESIGN OF BELT DRIVE AND DRIVEN PULLEYS

Since the door is move (open and close) by the power transmitted from shaft by the
timing belt drive. The tow pulleys should be designed.
_ Tow pulleys have equal pitch diameter (d)
n1
_ The speed ratio ( ) = 1
n2
The module (m) = 3mm (same to module of belt)
Pitch diameter of pulley (d) = 120mm.

FIG

The teeth are of trapezoidal shape, the belt dimensions are based on the following
proportions.
Tooth height (h)= (0.6 to 0.9)m say 0.7*3mm 2mm
The narrowest part of the tooth (s) = (1 to 1.2)*m
say (s) = 1.1*3mm = 3.3mm 3.2mm(standard)

Number of teeth on pulley ( z p ) =40 (calculated).

H = 4mm
= 0.6mm
=40 0

for module (m) = 3mm recommended.

The pitch diameter (d) = 120mm out side (addendum circle) diameter of pulley
d a = d - 2 +k

Where = distance from the bottom of the tooth spaces to the load charring layer =
0.6mm.
K = 2*10 5 * *z p *

F
= correction factor taking belt deformation in to account, mm
b

F
= peripheral force transmitted by the belt per unit width N/mm
b

= yielding of the belt material,(mm/N)

= 1.429mm/N for module (m) =3mm

Width (b) = 25.4mm (calculated)

Peripheral force acting on the pulleys or useful load of a belt
2 * K *T
, where T- torque on the pulley of diameter d.
d
2 * 1 * 14323.9 N / mm
=
k = dynamic load and service factor
120mm

F=

F= 239N

for steady starting load 120% of normal load k=1

120W * 60

T = 2 * * 80rpm = 14.3239Nm
K= 2*10 5 * *Z p *

F
b

= 2*10 5 * 1.429mm/N * 40*

239 N
25.4mm

K = 0.010757
Out side circle diameter of pulley (d a ) = d - 2 + k
d a = 120 (2*0.6) + 0.010757
d a = 118.8mm
- the force acting on the shafts from the drive is
Q = (1 to 1.2) F , say 1.2 *239N = 286.8N
Q= 287N
3.13 - WORM GEAR SHAFT DESIGN
The material of shaft is the same to that of the worm shaft.
Assume
-neglect the shaft weight and pulley weight.
-the shaft is subjected to both bending and torsion.
-use maximum shear stress theory, because of ductile shaft material.
-the shaft will design by considering key at worm gear and pulley attached.
Consider the weight of worm gear made of phosphor bronze

g A b

=8860 9.81

0.14 2
.018 N
4

= 24N.

where g =density of gear

g=gravitational acceleration
A= area of gear &
b=face width of gear

fig

Three components of force acting on worm gear shaft are,

Axial force (F ag ) =47.75N.
Tangential force (F tg ) =212.9N.
Separation (radial) force (F r ) =43.54N.
Weight of worm gear =24N.
Q t (horizontal force due to belt) =287N.
BENDING MOMENT DIAGRAM

FIG

Resultant bending moment at B=

9280

1009.52

=9334.7Nmm

Resultant bending moment at C= 9758 0 =9758Nmm.

M b max=at point C=9758Nmm.
2

Mt =

120 60
=14.32Nm=14323.9Nmm.
2 80

Let the material for shaft is ductile steel (S yt =400N/mm 2 ) using maximum shear stress
theory, let F.O.S=3
0.5 S yt
0.5 400
max =

=66.67N/mm 2
3
3
16
16
2
M 2b M t
97582 14323.92 10.98mm
d3=
max
66.67
Say. d=14mm stand.

DESIGN FOR TORSIONAL RIGIDITY

Permissible angle of twist =0.3deg/m machine tool shafting and 3deg/m for line shafting
G=80 10 9 N/m 2

584 M t L 584 14.32 0.1

=
80 109 0.014 4
Gd4
=

0.272
=2.72deg/m <3deg/m.
0.1

The shaft is less than permissible angle of twist there fore the shaft is safe for torsion
rigidity.
3.14 DESIGN OF WORM GEAR KEY
The function of key is to prevent the relative motion between the hubs of the worm gear
and the shaft, which carries the worm gear. The key transmits the torque from the worm
gear to the shaft. Square sunken key is select for its wide application in industrial
machinery. It is subject to considerable crushing and shearing stress. Material for square
sunk key is selected to be mild steel (C25Mn75) with yield strength (Syt = 280 N/mm2
), and the shaft material is ductile steel

(S yt = 400N/mm2). It is known for square

key (w = t), the permissible crushing stress is at least twice of the permissible shearing
stress. Consider factor of safety (fos) = 2. According to maximum shear stress theory:
max( s )

max( k )

S yt
2 fos
S yt
2 fos

400
= 100N/mm2
2 2

280
= 70N/mm2
2 2

The maximum torque transmitted by shaft and key:

max( s ) d 3
100 143
T=
=
= 53878.3Nmm
16
16
Consider the failure of key due to shearing
d
d
14
3.5mm , say w t 4mm
where, w t
2
4
4
Thus 53878.3 l 4 70 3.5
l 27.5mm

T = l w k

Consider the failure of key due to crushing

T l

t
d
ck
2
2

but ck 2 k 2 70 140 N / mm 2

4
14
140
2
2
l 27.04889mm .
Say l 30mm
53878.3 l

Therefore the dimension of small key is:

4 4 30mm

3.15 Pulley support axle design

Two pulleys which have equal pitch diameter are available. One
fixed on output shaft of motor and the other on the axle of 170mm
long attached on the top plate horizontally with center
distance(c)=2700mm.the axle is fixed and the pulley is rotate at
one end.
Therefore the axle is subjected to bending and torsion due to
rotating pulley. Due to force (Q)=287N coming from belt .Let, take
the axle as cantilever beam.
The material for axle to be alloy steel (1045 HR)
yield strength ( S yt syt=414N/mm )
(max)= /2*f.o.s

Let factor of safety=3

(max)=414/2*3=69N/mm 2
Length of axle =150mm
fig

M
V=p=287N
M
(max)=
=
D=19.69mm ,Say=30mm
Bending deflection
I=
E=207000N/

=0.0392mm
Torsion rigidity

,G=79000N/
=

=0.01960

=0.131 /m < 3 /m
Since the angel of twist

of the axle is less than the permissible value,

the axle is safe in accordance of torsion rigidity.

CHAPTER FOUR
4 - DOOR OPERATING COMPONENTS DESIGN
4.1 DETERMINATIONS OF DOOR SIZE AND SHAPE
-

4.1.1 Weight and dimension of door

First find the volume of the door made from aluminum part.

Aluminum part
1 Two sides of the door frame thickness = 45mm
v 1 = 2 (2060

55 45)

= 10,147500mm3

2 upper and lower part of doorframe,

v 2 = 2 (830 55 45)
= 4108500mm3
middle part of door frame
v 3 = 1 (830 150 45)
= 5602500mm3

volume of frame to be filled by glass

v4 = 2 (1840 3 10 ) + 4(850 3 10 )
= 212400mm 3
Total volume of frame (v tal ) = (v1+v2+v3)-v4
= (10147500+4108500+5602500)-212400
= 19646100mm 3

mass
,
volume
Mass = Al *vtot

Al =

where Al = 2650kg/m3

= 5650*0.0196461
m = 52.06kg
Weight of aluminum frame of single leaf of door = 52.06kg * 9.81m/s2 = 510.73N
The volume of glass with thickness (t) = 3mm is:
Volume of upper glass (v ug ) = (850*1026*3) mm3
= 2601000mm3
Volume of lower glass (v lg ) = (850 * 820 *3) mm3
= 2091000 mm3
v Tot = v ug + v lg =2601000mm3 +2091000 mm3
= 4692000mm 3 = 0.004692m 3
gl = 2600kg/ m 3
Mass of glass (m g ) = gl vTot
= (2600*0.004692) kg
m g = 12.199kg
Weight of glass (w g ) = (12.199*9.81) N
=119.67N
Total weight of single leaf of door = weight of aluminum frame + weight of glass
= 510.73 + 119.67 = 630N
4.1.2 FORCE REQUIRED TO MOVE THE DOOR LEAFS

Force required moving the door with constant velocity is (F)

The door has four rollers (tow at bottom and tow at top) on single leaf and eight rollers
for double leaf (all the system)
T= TO +

fr
Fr
r

where T = the resistance force to motion in anti friction

roller contact slide ways

T o = initial friction force 0.4kg/f (3.9N) on each roll way face for roller contact slide
ways.
r=radius of the rolling element
fr = coefficient of rolling friction taken equal to 0.00icm for steel(beam) roll ways and
0.0025cm for cast iron fall ways.
Fr = applied force (weight of door) on single roller = 315N.
Assumption
The rolling contact between roller and beam is as the same as rolling contact in the roller
Bearing between ring and cylindrical roller with line contact.
Roller diameter (d) =(36-16) = 20mm , r =10mm
Where 36mm =outside diameter
2(8) mm =bore diameter.
The resistance force to motion of the roller in single roller is
fr
*Fr
r
0.01
T = 3.9N +
*315N
10

T=T O +

T =4.215N

resisting force to the motion for one roller.

FORCE REQUIRED TO MOVE THE DOOR

a) for the door attached to the lower belt is
From equilibrium system (moment summation) =0

FIG

M
F1 =

=0

T [(2 * 1.051) (2 * 1.162)]

N
1.23

4.215 * (2.102 2.324)

N
1.23

F 1 = 15.2N

force required to move the left or door leaf to be fixed on lower belt.

b) Force required moving the door leaf attached to the upper belt.
Fig

=0
T [( 2 * 1.051) (1.162)]
F2 =
N
1.35
=

4.215 * 4.426
N
1.35

F 2 = 13.8N are force required to move the right or door leaf to be fixed on upper belt.
Total force required to move door leaf left and right at the same time (F)
F = F1 + F 2
=15.2N + 13.8N
F = 29N
4.2 - DESIGN OF DOOR HOLDING BEAM AT THE TOP
The beam, which supports the door, will be fixed at the top and bottom of the door.
USEAGE OF THE BEAM
Design of this beam is very critical, because the door weight will be carried by it. The
door slides by the help of two rollers attached on each leaf of door.
DESIGN CONSIDERATION
The strength of beam (bending)
The size and shape of beam
Deformation(rigidity)
DESIGN INPUT
Determining the size of each leaf of door
Determining the weight of each leaf of door
DESIGN ASSUMPTION

The door has two leafs, each weights and sizes are equal
The weight of the door is equally distributed

The door is supported by two rollers at the top and bottom

which have equal distance from either side.
The door size is practical. Which is our college building c
entrance.

THE DOOR SIZE AND WEIGHT

The door weight is calculated according to the material it made and density of the
material. The weight of single leaf = 64.22kg = 630N.for double leaf = (630*2) = 1260N
The door size for single leaf is

Figure

The supporting rollers fix at (b=150mm) from each edge. Each roller weights equally
(630/2N) = 315N, since they have equal distance from edges.
BEAM DESIGN
The length of the beam is twice the door length plus allowance
For single leaf (940*2) +100(allowance) = 1980mm.
For double leaf (1980*2) = 3960mm
Total length of beam = 3960mm supported at two ends and middle (1980mm).
Figure

Loading condition
The worst condition to design the beam is when each leaf of the door is in the following
position.

Figure
P = 315N (one roller can carry)
MATERIAL SELECTION
The material for beam to be steel (0.2% carbon) cold rolled with yield strength =
400Mpa.

Considering for strength point of view

To find the suitable cross-section of beam holding the door, first find the maximum
bending moment (By the use of B.M diagram.)
Figure

Bending moment diagram

Maximum bending occurs at point D,E, F and G. M b max = 211.05N.m.
We can consider the determination of the size of beam selection that will satisfy
allowable stresses in both flexure and shear. In heavy loaded short beams the design is
usually governed by the shearing stress, but in longer beams the flexure stress generally
governs, because the bending moment varies with both load and length of beam. Shearing
is more important in timber beam than in steel beam, because of the low shearing strength
of wood.
Flexure formula
M
C
d
d 4
all = b max
, for circular I =
, C=
2
64
I
all =

32 M b max
d 3

, all for steel =

S yt
FOS

, all =

400 N / mm
= 133.33N/mm ,
3

let ( FOS =3)

d3=
d=

32 M b max
32 211.05 N / m
=
all
133.33 106 N / m

0.02526m

let d = 30mm (standard)

4.3- DESIGN OF DOOR HINGING COMPONENTS AT THE TOP OF

DOOR
Components used to support the roller and fix to the upper part of the door are:
1. roller (two for single leaf )
2. roller fix axle (one for one roller)
3. box channel (one for one roller)

4. cap-screw used to fix the box to the top door (four for single roller)
MATERIAL SELECTION
Materials listed below are selected for the components according to its operation and load
applied. The material hardness, fatigue strength and wear resistant abilities are
considered.

components

Quality in
number

Upper roller

Selected
material
grade

Yield
strength
(N/mm 2 )
400N/mm

Hardness(HB)

380N/mm
460N/mm
400N/mm

217
241
179

179

30C 8
2
3
4

Roller fixing axle

Roller holding box
Cap-screw

4
4
(4*4) = 16

40C 8
50C 4
30C 8

Table ____ mechanical properties of plain carbon steel

4.3.1-UPPER ROLLER DESIGN
Upper rollers are used to roll the door left and right easily with small belt force. Two
rollers are attached to the top door with equal distance (d = 150mm) from each edge of
the door. For two leaves door four rollers to be attached and each roller carry 315N. The
roller rolls on 30mm diameter beam. To reduce the contact surface of beam and roller, the
roller arc to be cut greater than the diameter of beam.
The roller center hole should be press fitted to the axle passing through it.

Figure

4.3.1-DESIGN OF ROLLER FIXING AXLE

Axle is used for shaft that supports rotating elements like wheel, hoisting drum,
rollers etc and that is fitted to the housing by means of bearings. Axle subjected to pure
bending moment due to transverse loads like bearing reactions.
Figure

Where
F is half weight at one roller = 157.5N

all =

M b max C
=
I

all =

S yt
32 M b max
, all for steel =
3
d
FOS

380 N / mm 2
3

= 126.67 N / mm 2 let ( FOS

=3)
32 3540 Nmm
126.67 N / mm 2
d = 6.58 mm, let d = 8mm (standard)
d3 =

Deflection at the center

=

FL3
48 EI

- deflection at the center of centrally loaded beam , E = 207*10 9 n/m

I=

d 4
64

* (0.008) 4
=
64

315 * (0.025)3 * 64
, 2.46 * 106 m = 0.00246mm
48 * 207 * 109 * * (0.008) 4

4.3.3- BOX CHANNEL DESIGN

Box channel is used to join the door at the top to the roller in appropratesize.
The number of channel used for tow leafs of door are four which is equal to the number
of rollers.

FIG

The hole on the side makes stress concentration to increase.

FIG
Let on each side hole the p b = 157.5N
p
b = b ,
where - b = allowable bearing stress
Ab
p b = bearing force
A b = bearing (contact area)

all

s yt

460 N / mm 2
fos
3
153.3 N / mm 2

all

Ab =

pb
,
b

t*d =

pb
b

pb
157.5 N
=
d b
8 * 153 N / mm
t= 0.13mm

t=

Let t= 5mm to be more safe.

4.3.1- DESIGN OF FASTNER (CAP-SCREW)
Cap-screw is used to fix the box channel and the door. Cap screws differ from tap bolt in
the following respects.
i)
Cap screws are small compared with tap bolt.
ii)
A wide variety of shape as are available for the head of cap screw. On the
other heat tap bolt has hexagonal or square head.
Cap screw types (according to their head)
a) hexagonal
b) fillister
c) button
d) flat
e) hexagonal socket head

Flat type is the most preferred to our system because the head left over may
decrease the space for roller.
FIG

The threaded portion of cap screw is subjected to tensile stress due to weight of the door.
Let factor of safety =6
Permissible tensile stress t

s yt
fos

400
=66.67N/mm 2
6

pb
d c 2
4

d c =1.226m

78.75
66.67 = d c 2
4

d=

dc
1.226m
=
0.8
0.8

d = 1.53mm

M 4 from standard

Where p - weight of on single roller = 315N , p for each cap screw p 1 =

p
4 screw

=78.75N
d c - Minor diameter of an imaginary cylinder that bounds the roots of an external
thread.

4.4- DESIGN FOR LOWER ROLLER AND GUIDEWAY

The lower part of the door will design for two purposes.
i)
Rollers attached to the bottom of the door to support up ward weight of the
door also to decrease the force apply to move the door.
ii)
The guide way used to correct positioning of the moving door.
The components: dimension of components and the material in which the components
made of all the same to the upper rollers. But roller holding channel may differ in
structure and size.
The beam on which the roller rolls is 30 mm in diameter and 3960mm long fix in the
guide way.

4.4.1- ROLLER HOLDING CHANNEL DESIGN.

FIG

The structure of roller holding components has inverted u channel. number of rollers
and screws are equal (the same) to the upper part of the door.
The guide way
The guide way will have rectangular hole in the flour which is 3mm (allowance) distance
from the wall or column internal edge.
Its dimension will be 62mm deep, 50mm wide and 3960mm long. It is preferable
covering inside the guide way with sheet metal excluding the above dimension.
4.5-BOLT DESIGN
The bolt to be designed may be hexagonal head and nut which carries the motor .the bolt
is used to fix the electric motor vertically tow below motor and tow above motor.
The bolt is subjected to both shear and tensile stress .
Shear stress due to the weight of motor and gear drives attached on it,
Tensile stress is due to the belt drive.
_ consider the weight of motor and gears = 4kg* 9.81m/s2 = 40N
_ The maximum force acting on out put shaft with belt = 287N (calculated).
N = number of bolts.
Consider tensile stress
t = permissible tensile stress for medium carbon steel

t =

alt
480
=
= 320N/mm2
fos
1 .5

280 N
F
t =
=
d 2
n*
n* A
4

d=

, d=

280 * 4
n * * t

1120
= 0.527mm
4 * * 320

considering shear stress

t = permissible shear stress for medium carbon steel =

40
40
=
=
d2
n *
nA
4

alt
fos

380
=253.33N/mm2
1 .5

d=

160
n * * t

160
= 0.224mm
4 * * 253.33

Adopt that the safe diameter of bolt as M 10*1.5

4.6-COLUMN DESIGN
Column buckling elastic instability
We normally think of deflections with in the elastic range as varying linearly with load.
Several notable exceptions occur all of which involve subjecting relatively long, thin
portions of material to compressive stress. Perhaps the most common of these are long,
slender columns loaded in compression.
Example of column includes columns in buildings, structural compression links (as
in bridge) piston connecting rods, coil springs in compression, and jack screws.
Euler column buckling
Eulers analysis pertains to fig below which shows along slender column such as an
ordinary yardstick load in compression.
Euler assumption
The ideal case of a perfectly straight column, with the load precisely axial,
The material perfectly homogeneous, and stresses with in the linear elastic range.
If such a column is loaded below a certain value, p cr , any slight lateral displacement
given to the column. An internal elastic moment more than adequate to restore
straightness to the column, when the lateral displacing force is removed. The column is
then elastically stable. When per is exceeded the slightness lateral displacement results in
an eccentric bending moment p.e greater than the internal elastic restoring moment and
the column collapses. Thus the loads in excess of p cr render the column elastically
unstable.
The load applied to the commune laterally is the worst condition when the door is in
opening condition.
The loads to be assumed are:
- The weight of the single leaf door for each column
- The weight of the door acting components to be fixed at the top of the door (for two
columns).
-the weight of the plate caring the motor pulley etc
-The belt drives tangential forces.
Load analysis
1) Weight the single leaf door is 630N (calculated)
2) Weight of components:Motor=4 9.81 40N
Pulley & belt=3 9.81 30N
=70N for two columns
For a column

70
=35N
2

3) The weight of the plate (rectangular)

Area of plate= L h =4000 400 1600000 mm 2 or =1.6m 2
Thickness of plate=3mm
Material for plate= steel, carbon
=7.7 10 6 g/m 3 =7700kg/m 3
Weight=volume density
=1.6 0.003 7700 9.81 =363N for two columns.
For single column=

363
181.5 N .
2

Total load p on single column=630+35+181.5N=846.5N vertical.

Horizontal=

120W 60

=
=239N.
t 2 80rpm

Fig

Some of the rules of thumb for buckling of columns

1) A column is made of ductile material like steel, and whose length
is more than eight times its least lateral dimensions is likely to
buckle and should be treated as column.
2) A column made of brittle material like cast iron and whose length
is more than six times of its least lateral dimensions is likely to
buckle and should be treated as column.

Fig
Important parameters
Slenderness ratio=
K=

I
A

L
,
K

L=length of column (mm)

K=least radius of gyration of X-section about x-axis

I=least moment of inertia X-section (mm 4 )

A=area of X-section (mm 2 )
When slenderness ratio <30, there is no effect of buckling.
Steel columns with a slenderness ratio not greater than 100, are considered as short
column for ductile material these with slenderness ratio greater than 100, are long
columns.
When slenderness ratio is >103.7 using Eulers equation,

n 2 E A
L 2
=
cr

K2

cr

=critical load (N)

n=end fixity coefficient

E=modulus of elasticity (N/mm 2 )
A=area of cross section (mm 2 )
When slenderness ratio is <103.7, use Johnsons equation

1
A 1

=
2
cr S yt
4 n E K

yt

Our column length=2260mm.

Cross sectional area=b h
Let b=2h,
Let the column long column (made of steel) 45C8 (

yt

=380N/mm 2 and

E=207000N/mm 2 ) since the column is long (length compared to least of lateral

dimension) using Eulers equation is preferable.
b h3
I
=
=
A
12 b h

K=

P
P

h2
12

K=0.2886h

N=4 (for both ends fixed)

F.O.S=2.5
rc

=P F.O.S =846.5N 2.5=2116.25N.

n 2 E A

rc

4 2 207000 2 h 2

=2116.25N=
=

ok.

2260

.2886h

1.29775 1011
=16344064.89h 2
h2
h 4 =7940.19
h=9.43 15mm.
b=2h=2 15=30mm

L
2260
=
=522>103.7 long column
K
.2886 15

CHAPTER FOUR
PROGRAMMABLE LOGIC CONTROLLER (PLC) AND SENSOR
WIRING
5.1- INTRODACTION
Control engineering has evolved over time. In the past humans was the main method for
controlling a system. More recently electricity has been used for control and early
electrical control was based on relays. These relays allow power to be switched on and
off without a mechanical switch. It is common to use relays to make simple logical
control decisions. The development of low cost computer has brought the most recent
revolution, the Programmable Logic Controller (PLC). The advent of the PLC began in
the 1970s, and has become the most common choice for manufacturing controls.

PLCs have been gaining popularity on the factory floor and will probably remain
predominant for some time to come. Most of this is because of the advantages they offer.
Cost effective for controlling complex systems.
Flexible and can be reapplied to control other systems quickly and easily.
Computational abilities allow more sophisticated control.
Trouble shooting aids make programming easier and reduce downtime.
Reliable components make these likely to operate for years before failure.
5.1.1- LADDER LOGIC
Ladder logic is the main programming method used for PLCs. Ladder logic has
been developed to mimic relay logic. The decision to use the relay logic diagrams was a
strategic one. By selecting ladder logic as the main programming method, the amount of
retraining needed for engineers and trades people was greatly reduced.
Modern control systems still include relays, but these are rarely used for logic. A relay is
a simple device that uses a magnetic field to control a switch.
Generally, a PLS is a computer based controller that uses inputs to monitor a process,
and uses outputs to control a process using a program.

5.2- OBJECTIVES
The main objectives of using PLC in this project are:
To know general PLC issues.
To be able to write ladder logic programs.
To understand the operation of a PLC.
Mainly, to control the opening and closing of the door when somebody enters and
leaves the door.

5.3- PLC connections

When a process is controlled by a PLC it uses inputs from sensors to make decisions
and update outputs to drive actuators. The process is a real process that will change over
time. Actuators will drive the system to new states.

Fig ----. The separation of controller and process.

5.3.1- PLC HARDWARE CONFIGURATIONS

Many PLC configurations are available, even from a single vendor. But, the most
essential components are:
Power Supply - This can be built into the PLC or be an external unit. Common voltage
Levels required by the PLC (with and without the power supply) are
24Vdc, 120Vac, 220Vac.
CPU (Central Processing Unit) - This is a computer where ladder logic is stored and
Processed.
I/O (Input/Output) - A number of input/output terminals must be provided so that the
PLC can monitor the process and initiate actions.
Indicator lights - These indicate the status of the PLC including power on, program
running, and a fault.
Inputs for PLC of automatic door designed are:
Sensor (optical) senses when somebody enters and leaves the door.
Limit switch- used to limit the opening and closing position of the door.
Outputs for PLC of automatic door designed are:
Motor (on/off)
Alarm light (when the door open)

5.4- SENSOR WIRING

Inputs for a PLC come in a few basic varieties, the simplest are AC and DC input.
Sourcing and sinking inputs are also popular.

Sinking sensors allow current to flow into the sensor to the voltage common, while
sourcing sensors allow current to flow out of the sensor from a positive source. For both
of these methods the emphasis is on current flow, not voltage. By using current flow,
instead of voltage, many of the electrical noise problems are reduced.
When discussing sourcing and sinking, we are referring to the output of the sensor that
is acting like a switch. In fact the output of the sensor is normally a transistor that will act
like a switch (with some voltage loss). A PNP transistor is used for the sourcing output,
and an NPN transistor is used for the sinking input. When discussing these sensors the
term sourcing is often interchanged with PNP, and sinking with NPN.

Fig ____.NPN (sinking sensor)

Fig ____.PNP (sourcing sensor)

5.5- DESCRIPTION OF THE PROCESS.

REFERANCES
-Mechanical designers work book, gearing editors in chief Joseph E. shigley
Prof. emeritus . charles R.Mischke
Prof. of mechanical engineering.
-Mechanical engineering design
Edward shigley Joseph L.
- Mechanical design peter R.N.Childs (second edition).
-Machinery handbook